Power tool

ABSTRACT

A power tool includes a housing. A motor is housed in the housing. A platen is driven by the motor. The housing includes a first housing part, a second housing part and a third housing part. The housing defines a battery receptacle portion configured to receive a removable battery pack which powers the motor. Each of the first housing part, the second housing part and the third housing part form part of the battery receptacle portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/833,853 filed on Mar. 30, 2020 which is a continuation of U.S. patentapplication Ser. No. 15/249,818 filed on Aug. 29, 2016, now U.S. Pat.No. 10,632,589. The entire contents of both are incorporated herein byreference.

FIELD OF THE INVENTION

The present invention relates to power tools.

BACKGROUND

There are various existing power tools. It is desired to provide a powertool with an efficient housing construction.

SUMMARY

According to an aspect of an exemplary embodiment, there is a power toolcomprising which includes a housing. A motor is housed in the housing. Aplaten is driven by the motor. The housing includes a first housingpart, a second housing part and a third housing part. The housingdefines a battery receptacle portion configured to receive a removablebattery pack which powers the motor. Each of the first housing part, thesecond housing part and the third housing part form part of the batteryreceptacle portion.

The battery receptacle portion may include a first rail and a secondrail, the first and second rails are configured to engage rails of theremovable battery pack.

The first, second and third housing parts may each form part of at leastone of the first rail and the second rail.

The first housing part and the second housing part may together form thefirst rail.

The third housing part may form the second rail.

The first housing part may be a first side housing part. The secondhousing part may be a second side housing part. The third housing partmay be a top housing part.

The first side housing part and the second side housing parts may formsides of the housing when the platen is disposed on a flat horizontalsurface and the top housing part forms a top part of the housing whenthe platen is disposed on a flat horizontal surface.

The power tool may be a sander.

The first rail may be generally perpendicular to a rotational axis ofthe motor.

An electrical connector may be configured to electrically engage withthe battery pack is held between the second housing part and the thirdhousing part.

According to another aspect, there is an exemplary embodiment of asander, the sander including a housing, a motor housed in the housing,and a sanding platen which is driven by the motor. The housing includesa first housing part, a second housing part and a third housing part.The housing defines a battery receptacle portion configured to receive aremovable battery pack which powers the motor, the battery receptacleportion including a first rail and a second rail, the first rail and thesecond rail configured to engage rails of the removable battery pack.The first rail is comprised of the first housing part and the secondhousing part.

The third rail may be comprised of the third housing part.

The sander may further include an electrical connector held between thesecond housing part and the third housing part.

The first housing part may be a first side housing part. The secondhousing part may be a second side housing part. The third housing partmay be a top housing part.

The first side housing part and the second side housing parts may formsides of the housing when the platen is disposed on a flat horizontalsurface and the top housing part forms a top part of the housing whenthe platen is disposed on a flat horizontal surface.

The first rail and the second rail may be generally perpendicular to arotational axis of the motor.

The first housing part, the second housing part and the third housingpart may be made of a plastic material.

According to another aspect, there is an exemplary embodiment of a powertool including a housing, a motor housed in the housing, and a platenwhich is driven by the motor. The housing includes a first housing part,a second housing part and a third housing part. The housing defines abattery receptacle portion configured to receive a removable batterypack which powers the motor, the battery receptacle portion comprising afirst rail and a second rail, the first rail and the second railconfigured to engage rails of the removable battery pack. The thirdhousing part is a top housing part that forms a top part of the housingwhen the platen is disposed on a flat horizontal surface. The secondrail is comprised of the third housing part.

The first rail may be comprised of the first housing part and the secondhousing part.

The sander may further include an electrical connector held between thesecond housing part and the third housing part.

The first housing part may be a first side housing part. The secondhousing part may be a second side housing part. The first side housingpart and the second side housing parts may form sides of the housingwhen the platen is disposed on a flat horizontal surface.

The power tool may be a sander.

According to another aspect, an exemplary embodiment includes method ofconstructing a power tool. The method includes providing a first housingpart, a second housing part and a third housing part. Moving the firsthousing part and the second housing part relatively toward each other tocapture a motor therebetween and assembling the first housing part andthe second housing part together. Moving the third housing partrelatively towards the assembled first and second housing parts tocapture a connector component therebetween.

The first housing part, the second housing part and the third housingpart may be comprised of plastic.

The connector component may be an electrical connector component.

The electrical connector component may be configured to engage with abattery pack to power the power tool.

The first housing part may include a first side part which forms a firstside of the power tool when the power tool is placed on a flathorizontal surface.

The second housing part may include a second side part which form asecond side of the power tool when the power tool is placed on the flathorizontal surface.

The third housing part may include a top part which forms a top of thepower tool when the power tool is placed on the flat horizontal surface.

The first housing part and the second housing part may each form part ofa first rail configured to engage a first rail of the battery pack.

The third housing part may form a second rail configured to engage asecond rail of the battery pack.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary embodiment of a sander;

FIG. 2 is another perspective view of the exemplary embodiment of thesander;

FIG. 3 is a perspective view of the housing of the exemplary embodimentof the sander;

FIG. 4 is a side view of the exemplary embodiment of the sander;

FIG. 5 is another perspective view of the exemplary embodiment of thesander with the battery pack removed;

FIG. 6 is a top view of the exemplary embodiment of the sander;

FIG. 7 is a perspective view of the first and second housing parts ofthe exemplary embodiment of the sander;

FIG. 8 is a perspective view of the exemplary embodiment of the sanderwith first and third housing parts removed illustrating internal partsof the sander;

FIG. 9 is a side view of the exemplary embodiment of the sander withfirst and third housing parts removed illustrating internal parts of thesander;

FIG. 10 is an exploded perspective view of the housing of the exemplaryembodiment of the sander;

FIG. 11 is another exploded perspective view of the housing of theexemplary embodiment of the sander;

FIG. 12 is a perspective view of an exemplary embodiment of the batterypack;

FIG. 13 is a perspective view of the exemplary embodiment of the batterypack with part of the battery pack housing removed to illustrate thebattery cells;

FIG. 14 is a side view of the exemplary embodiment of the battery packwith part of the battery pack housing removed to illustrate the batterycells; and

FIG. 15 is a top view of the exemplary embodiment of the battery packthe battery pack housing removed.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

An exemplary embodiment according to the present application is shown inFIGS. 1-15 . The exemplary embodiment illustrates a power tool, inparticular, a cordless random orbit sander (ROS) 10. The sander 10 ofthe exemplary embodiment is a random orbit sander. The sander 10 ispowered by a removable and rechargeable battery pack 100. The sander 10is turned on and off by a switch 11. As is well known, the sander 10rotates a platen 200 in a random orbit to remove materials. The sander10 of the present exemplary embodiment is a random orbit sander, but inother exemplary embodiments the sander could be a different type ofsander, such as an orbit sander, a detail sander or a quarter-sheetsander. As shown, the sander 10 further includes a dust chute 130 whichdirects dust into a dust bag 135 for collection.

The housing 20 of the sander 10 is comprised of three housing partsincluding a first housing part/first side part 30, a second housingpart/second side part 40 and a third housing part/top housing part 50.The three housing parts are each made of plastic and are assembledtogether by screws. The three housing parts 30, 40 and 50 can be seenthroughout the drawings and are shown in exploded views in FIGS. 10 and11 . The housing parts 30, 40, 50 come together to form a batteryreceptacle portion 60. As will be appreciated, the battery receptacleportion 60 receives a removable battery pack 100 which powers the sander10.

Internals of the sander are shown in FIGS. 8 and 9 , in which the firstside part 30 and the top housing part 50 have been removed. As shown inFIGS. 8 and 9 , a motor 80 rotates an output shaft 81 which rotates afan 83 and the sanding platen 200. A bearing 82 supports the outputshaft 81. The platen 200 receives the output shaft 81 in an eccentricmanner so that the platen 200 moves in an orbital motion when driven bythe motor 80.

As shown in FIG. 5 , the battery receptacle portion 60 includes a firstrail 42 and a second rail 51. It also includes an electrical connectionsection 62 which includes a number of electrical connectors 63. Theelectrical connectors 63 engage electrical connectors from the batterypack 100 so that the pack 100 can provide power to the motor 80. Thefirst rail 42 is made up of a rail section 31 from the first housingpart 30 and a rail section 41 from the second housing part 40. Thesecond rail 51 is formed from the top housing part 50. As seen, therails 42 and 51 are generally perpendicular to a rotational axis of themotor 80. They also run horizontally when the sander 10 is placed on aflat horizontal surface. Additionally, the electrical connector section62 is sandwiched between the second housing part 40 and the top housingpart 50.

The three part construction of the sander housing 20 allows for anefficient design, assembly and for construction of the rails 42 and 51.As can be appreciated, in order to assemble the sander 20, various partssuch as the motor 80 can be inserted into the second housing part 40.After that, the first housing part 30 and the second housing part 40 areconnected to one another to secure the motor 80 therebetween. Bringingthe first housing part 30 and the second housing part 40 together formsthe first rail 42 out of the rail section 31 from the first housing part30 and the rail section 41 from the second housing part 40. Theelectrical connector section 62 is inserted into the second housing part40 at the slot 65 shown in FIG. 7 . FIG. 7 shows the housing parts 30and 40 without the electrical connector section 62, which allows theslot 65 to be seen. After the electrical connector section 62 isinserted into the slot 65, the top housing part 50 is then connected tothe first and second housing parts 30, 40 to provide the second rail 51and to secure the electrical connector 62.

Some of the above steps may be done in various orders or configurations.For example, one or more of the motor 80, bearing 82, fan 83 and otherparts may be inserted into the first housing part 30 instead of thesecond housing part 40 so long as they can be clamped between the twohousing parts 30, 40. Additionally, the electrical connector section 62may be inserted before or after the first housing part 30 and the secondhousing part 40 are connected.

The three-part housing construction of the exemplary embodiment may haveseveral advantages. For example, clamping operations in more than onedirection can be performed. That is, the motor 80 can be held betweenthe first and second housing sections 30, 40. Due to its location andthe construction of the housing 20, the electrical connection section 62cannot is not clamped between the first and second housing sections 30,40. However, the electrical connection section 62 can be held betweenthe second housing section 40 and the top housing section 50.Particularly, the electrical connection section 62 can be inserted intothe second housing part 40 from a vertical direction. The top housingsection 50 can then be assembled onto the first and second housing parts30, 40 from the vertical direction to hold the electrical connectionsection 62 in place.

As will be appreciated, the exemplary embodiment of the presentapplication allows for multiple clamping or holding operations betweenhousing parts to take place. For example, the motor 80 can be heldbetween the first and second housing parts 30, 40 in a first operationin a first direction and the electrical connection section 62 can beheld between the top housing part 50 and the second housing part.

The battery pack 100 for powering the sander 10 is shown in furtherdetail in FIGS. 12-15 . FIG. 12 is a perspective view of the pack 100.FIG. 13 is a perspective view of the pack 100 with a lower part of thepack housing 201 removed. FIG. 14 is a side view of the pack 100 with alower part of the pack housing 201 removed. FIG. 15 is a top view of thepack 100 with the pack housing 201 removed.

The power tool battery pack 100 includes a set of rechargeable batterycells 220 disposed in a housing 201. The housing 201 includes guiderails 104 for engaging the rails 42 and 51 of the sander housing 20. Therails 104 slide between the rails 42, 51 and the rest of the sanderhousing 20 and the rails 42, 51 guide the battery pack 100 into placeand prevent it from moving away from the motor 80 area of the housing20. The battery pack 100 includes a latch 105 for securing the batterypack 100 in place. The latch 105 is biased upwardly by a spring (notshown) and the latch 105 can be moved by depression of the latchactuator 106, which may be integral with the latch 105. A battery packwith guide rails such as those shown these figures is more fully shownand described in U.S. Pat. No. 6,729,413, which is incorporated hereinby reference in its entirety. The battery pack 100 also includes aconnection section 103 through which the battery pack 100 can makeconnection with the sander 10. The connection section includes fouropenings 111, 112, 113 and 114.

FIGS. 13-15 each have at least part of the battery pack housing 201removed. As shown, the pack 100 includes a plurality of rechargeablebattery cells 220. A cradle 16 (FIG. 14 ) sits over the battery cells220 and a printed circuit board (PCB) 140 (FIG. 15 ) is connected to thecradle 16. The PCB 140 is in electrical connection with the batterycells 220. Electric connectors 121, 122, 123 and 124 are mounted on thePCB 140 and connect with power tools through the connection section 103,specifically openings 111, 112, 113 and 114 shown in FIG. 12 . Theelectrical connecters serve as terminals for the battery pack 100.Connector 121 may serve as a negative terminal; connector 122 may be atemperature terminal which relays information related to a temperatureof the battery pack; connector 123 may be an ID terminal which relaysinformation related to identifying the pack and connector 124 may be apositive terminal.

The battery pack 100 electrically connects with the sander 10 at thebattery pack electrical connector section 62. The electrical connectorsection 62 includes three electrical connectors 63. The electricalconnectors 63 connect with the positive, negative and temperatureterminals 121, 124 and 122 of the battery pack 10. The ID terminal 123of the battery pack 100 is used when charging the battery pack 100. Thebattery pack 100 may be charged by a separate battery pack charger (notshown).

While the invention has been described by way of exemplary embodiments,it is understood that the words which have been used herein are words ofdescription, rather than words of limitation. Changes may be made withinthe purview of the appended claims, without departing from the scope andspirit of the invention in its broader aspects.

What is claimed is:
 1. A power tool comprising: a housing; a motorhoused in the housing; an output shaft driven by the motor; a platenwhich is driven by the motor through the output shaft; wherein thehousing comprises a first housing part, a second housing part and athird housing part; wherein the housing comprises a battery receptacleportion configured to receive a removable battery pack which powers themotor; wherein the first housing part, the second housing part and thethird housing part are three separate pieces assembled together; whereinthe battery receptacle portion comprises a first rail and a second rail;wherein the first rail is formed at least partially from the secondhousing part; wherein the second rail is formed at least partially fromthe third housing part; wherein the first rail runs horizontally whenthe platen is placed on a flat horizontal surface; and wherein the firstrail is transverse to a rotational axis of the motor.
 2. The power toolof claim 1, wherein the first rail is parallel to the second rail. 3.The power tool of claim 1, wherein the removable battery pack includes abattery pack housing and a plurality of battery cells housed in thebattery pack housing; wherein the removable battery pack isrechargeable.
 4. The power tool of claim 1, wherein the first housingpart comprises a plastic material; wherein the second housing partcomprises a plastic material; and wherein the third housing partcomprises a plastic material.
 5. The power tool of claim 4, wherein thefirst housing part, the second housing part and the third housing partare assembled together by fasteners.
 6. The power tool of claim 5,wherein the first housing part, the second housing part and the thirdhousing part are assembled together by screws.
 7. The power tool ofclaim 1, further comprising an electrical connector section configuredto electrically engage with the removable battery pack; wherein theelectrical connector section is held between the second housing part andthe third housing part.
 8. The power tool of claim 7, wherein theelectrical connector section comprises a first electrical connector, asecond electrical connector; and a third electrical connector.
 9. Thepower tool of claim 1, wherein the first rail is generally perpendicularto the rotational axis of the motor; and wherein the second rail isgenerally perpendicular to the rotational axis of the motor.
 10. Thepower tool of claim 1, further comprising a fan; wherein the fan isdriven by the motor through the output shaft.
 11. A power toolcomprising: a housing; a motor housed in the housing; an output shaftdriven by the motor; a platen which is driven by the motor through theoutput shaft; wherein the housing comprises a first housing part, asecond housing part and a third housing part; wherein the housingcomprises a battery receptacle portion configured to receive a removablebattery pack which powers the motor; wherein the first housing part, thesecond housing part and the third housing part are three separate piecesassembled together; wherein the battery receptacle portion comprises afirst rail and a second rail; wherein the first rail is formed at leastpartially from the second housing part; wherein the second rail isformed at least partially from the third housing part; wherein the firstrail runs horizontally when the platen is placed on a flat horizontalsurface; wherein the first housing part comprises a plastic material;wherein the second housing part comprises a plastic material; whereinthe third housing part comprises a plastic material; further comprisingan electrical connector section configured to electrically engage withthe removable battery pack; wherein the electrical connector section isheld between the second housing part and the third housing part; andwherein the first rail is transverse to a rotational axis of the motor.12. The power tool of claim 11, wherein the first rail is parallel tothe second rail.
 13. The power tool of claim 11, wherein the removablebattery pack includes a battery pack housing and a plurality of batterycells housed in the battery pack housing; wherein the removable batterypack is rechargeable.
 14. The power tool of claim 11, wherein theelectrical connector section comprises a first electrical connector anda second electrical connector.
 15. The power tool of claim 14, whereinthe electrical connector section comprises a third electrical connector.16. The power tool of claim 11, wherein the first housing part, thesecond housing part and the third housing part are assembled together byfasteners.
 17. The power tool of claim 16, wherein the first housingpart, the second housing part and the third housing part are assembledtogether by screws.
 18. The power tool of claim 11, further comprising afan; wherein the fan is driven by the motor through the output shaft.19. A power tool comprising: a housing; a motor housed in the housing;an output shaft driven by the motor; a fan driven by the motor throughthe output shaft; an output member driven by the motor through theoutput shaft; wherein the housing comprises a first housing part, asecond housing part and a third housing part; wherein the housingcomprises a battery receptacle portion configured to receive a removablebattery pack which powers the motor; wherein the first housing part, thesecond housing part and the third housing part are three separate piecesassembled together; wherein the battery receptacle portion comprises afirst rail and a second rail; wherein the first rail is formed at leastpartially from the second housing part; wherein the second rail isformed at least partially from the third housing part; wherein the firstrail runs horizontally; wherein the second rail runs horizontally;wherein the first rail is transverse to a rotational axis of the motor;wherein the second rail is transverse to the rotational axis of themotor; wherein the first housing part comprises a plastic material;wherein the second housing part comprises a plastic material; whereinthe third housing part comprises a plastic material; further comprisingan electrical connector section configured to electrically engage withthe removable battery pack; wherein the electrical connector section isheld between the second housing part and the third housing part.
 20. Thepower tool of claim 19, wherein the output member is a platen; andwherein the platen is driven in a random orbit.
 21. The power tool ofclaim 19, wherein the electrical connector comprises a first electricalconnector, a second electrical connector, and a third electricalconnector.
 22. The power tool of claim 21, wherein the first electricalconnector is configured to engage a positive terminal of the removablebattery pack; and wherein the second electrical connector is configuredto engage a negative terminal of the removable battery pack.
 23. A powertool comprising: a housing; a motor housed in the housing; an outputshaft driven by the motor; a fan driven by the motor; an output memberdriven by the motor through the output shaft; wherein the housingcomprises a first housing part, a second housing part and a thirdhousing part; wherein the housing comprises a battery receptacle portionconfigured to receive a removable battery pack; wherein the firsthousing part, the second housing part and the third housing part arethree separate pieces assembled together; wherein the battery receptacleportion comprises a first rail and a second rail; wherein the first railis formed at least partially from the second housing part; wherein thesecond rail is formed at least partially from the third housing part;wherein the first rail extends horizontally when the output member isplaced on a flat horizontal surface; wherein the first rail isperpendicular to a rotational axis of the motor; further comprising anelectrical connector section configured to electrically engage with theremovable battery pack; wherein the electrical connector section is heldbetween the second housing part and the third housing part; and whereinthe electrical connector section comprises a first electrical connectorand a second electrical connector.
 24. The power tool of claim 23,wherein the second rail is parallel to the first rail.
 25. The powertool of claim 23, further comprising a bearing supporting the outputshaft.
 26. The power tool of claim 23, wherein the output member isconfigured to be driven in a random orbit.
 27. The power tool of claim23, wherein the first electrical connector is configured to engage apositive terminal of the removable battery pack; and wherein the secondelectrical connector is configured to engage a negative terminal of theremovable battery pack.
 28. The power tool of claim 27, wherein thefirst housing member comprises a plastic material; wherein the secondhousing part comprises a plastic material; wherein the third housingpart comprises a plastic material; wherein the first housing part, thesecond housing part and the third housing part are assembled together byfasteners; wherein the electrical connector section is configured toreceive the removable battery pack in a horizontal orientation when theoutput member is placed on a flat horizontal surface; wherein the outputmember is configured to be driven in a random orbit.
 29. The power toolof claim 23, wherein the first rail is formed at least partially by thefirst housing part.
 30. The power tool of claim 29, wherein the firsthousing member comprises a plastic material; wherein the second housingpart comprises a plastic material; wherein the third housing partcomprises a plastic material; wherein the first housing part, the secondhousing part and the third housing part are assembled together byfasteners; wherein the electrical connector section is configured toreceive the removable battery pack in a horizontal orientation when theoutput member is placed on a flat horizontal surface; wherein the outputmember is configured to be driven in a random orbit; wherein the firstelectrical connector is configured to engage a positive terminal of theremovable battery pack; and wherein the second electrical connector isconfigured to engage a negative terminal of the removable battery pack.